Case Study: Control system replacement
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Contract Scope:
As the existing process-control system became difficult to support, the decision was made to upgrade to a state-of-the-art system based on Siemens' TIA philosophy. The replacement was phased over several months to enable production to continue as the process was gradually migrated to the new system.
This system and services supplied by the Boulting Group enabled the integration, via middleware, to the enterprise-wide SAP/R3 system scheduling production at dozens of plants worldwide.
The architecture is based on S7/400H PLCs in hot standby, with a resilient Ethernet ring with Scalance network components linking to redundant WinCC Scada systems and middleware. At plant level, TP270 HMIs provide operator prompts with barcode scanners logging manual ingredient additions, weighed via Sirawex weighing modules.
ET200 Remote I/O, MicroMaster variable speed drives and TP270s are all connected via dual Profibus DP links.
Services supplied
- Detailed engineering and design
- FDS
- PLC & SCADA software
- Middleware integration
- CDM role as principal contractor
- Installation
- Re-engineering control panels
- FAT, SAT and commissioning
Equipment supplied
- New control panels
- Industrial Ethernet and Profibus Installation
- SCADA terminals and control room equipment
- UPS system
